Touch sensor assembly and method of manufacturing same

ABSTRACT

A touch sensor assembly may include a sensor mounting portion formed at a insulating substrate, and a soldering spot provided at the sensor mounting portion, wherein a touch sensor is stably fixed to the sensor mounting portion by the soldering spot. In addition, the touch sensor assembly according to an embodiment of the present disclosure includes a copper coating film coated on a insulating substrate, and a top layer printed on the copper coating film, wherein the copper coating film is protected by the top layer.

CROSS-REFERENCE TO RELATED APPLICATION

The present application is a Continuation of U.S. application Ser. No.14/977,605, filed Dec. 21, 2015, which claims the benefits of priorityto Korean Patent Application No. 10-2014-0189144 filed on Dec. 24, 2014,which is herein incorporated by reference in its entirety.

BACKGROUND

1. Field

A touch sensor assembly for household appliances and a method ofmanufacturing the same are disclosed herein.

2. Background

Generally, touch sensor assemblies are used for household appliances andmay include electrostatic capacitance sensors or sensors using aresistance cell, etc. Such sensors sense a user's touches, and perform asignal processing for operation of household appliances. Steel, anexterior member coated to have feeling of steel, or glass has beenwidely used for an exterior member, and a touch sensor assembly has beendeveloped to easily recognize a touch when a user touches a surface ofsuch an exterior member.

Refrigerators are household appliances for storing food in inner storagespaces at low temperatures. The refrigerator is configured to storestored food in an optimum state by cooling an inside thereof using chillair generated by heat exchanging with a refrigerant which circulates arefrigeration cycle. The inside of the refrigerator may be divided intoa refrigerator compartment and a freezer compartment, and a storagemember, such as a shelf, a drawer, and a basket, is provided in theinside of the refrigerator compartment and/or the freezer compartment.The refrigerator and the freezer compartments are covered by doors. Therefrigerator may be classified according to arrangement of therefrigerator compartment and the freezer compartment and a shape of thedoor.

Recently, refrigerators which include improved exteriors and variouscomfort systems according to trends toward gentrification andmultifunction are commercialized. For example, refrigerators of whichexterior members which constitute exteriors thereof are formed of steel,glass, or a material which is formed by being coated with a glass-likematerial and which include displays and operation systems having variousstructures for easy user manipulation have been developed. Arefrigerator developed based on above technique is disclosed in theKorean Patent No. 10-0634365, whose disclosure is incorporated herein byreference.

SUMMARY

An embodiment of the present disclosure is directed to provide a touchsensor assembly capable of increasing the recognition rate of a touch sothat a touch sensor is disposed at a correct position and stably fixedwhen the touch sensor is installed at a sensor printed circuit board(PCB), and a method of manufacturing the same.

In addition, an embodiment of the present disclosure is directed toprovide a touch sensor assembly capable of securing the operationalreliability of a touch sensor and improving the productivity thereof,and a method of manufacturing the same.

According to an aspect of the present disclosure, there is provided atouch sensor assembly including a sensor mounting portion formed at aninsulating substrate, and a soldering spot provided at the sensormounting portion, wherein a touch sensor is stably fixed to the sensormounting portion by the soldering spot.

In addition, the touch sensor assembly according to an embodiment of thepresent disclosure includes a copper coating film coated on theinsulating substrate, and a top layer (a protective layer) printed onthe copper coating film, wherein the copper coating film is protected bythe top layer.

A method of manufacturing a touch sensor assembly according to anembodiment of the present disclosure may include: forming a base of asensor PCB using an insulating substrate having a resin material;forming a copper coating film on the insulating substrate; printing atop layer on the copper coating film except a region of a sensormounting portion; forming a sensor support portion at the center of thesensor mounting portion; coating solder cream onto the sensor mountingportion and forming a soldering spot; mounting a touch sensor on thesensor mounting portion and covering the sensor support portion; andpressing and heating the touch sensor and fixing the touch sensor to thesensor mounting portion.

According to an embodiment of the present disclosure, the touch sensormay be installed to be fixed on the sensor PCB by a soldering spot towhich a gel-typed solder cream is applied. Accordingly, the touch sensormay be stably fixed onto the sensor PCB without damage, and a correctposition may be maintained, and thus, there are effects that thesensitivity of the touch sensor is maintained constantly, and theoperational reliability of a touch sensor is secured.

Particularly, a touch sensor having a piezo type which is sensitive totension is sensitive because a normal operation is difficult even whenthe touch sensor is slightly misaligned with a sensor hole. Accordingly,when the center of the touch sensor is shifted from the center of thesensor hole, and a touch operation unit and an elastic member are notcorrectly aligned with the touch sensor, the touch sensor may abnormallyoperate even when the touch operation unit is touched. However,according to an embodiment of the present disclosure, since the touchsensor is fixed on a correct position by a soldering spot, there is amerit in that a correct fixed position of the sensor is secured.

In addition, in the method in which the touch sensor is fixed using thesoldering spot, not only a thickness thereof is remarkably smaller thanthat of a conventional soldering, but also the touch sensor iseffectively fixed, and thus, the touch sensor can be prevented frombeing inclined or damaged.

In addition, since the soldering spot is formed by coating solder creamonto a mounting position of a sensor using a printing method, thesoldering spot be formed by an automatic method instead of a user'smanual method. In addition, since an entire process including supplyingthe touch sensor using a feeder, and attaching sensor by heating can beautomatized, workability and productivity are increased and uniformreliability is secured.

In addition, when the touch sensor is installed at the sensor mountingportion using the soldering spot, since the touch sensor can be stablyand firmly fixed, electrical conductivity can be secured sufficiently.Accordingly, since a part of the sensor PCB can be formed using a coppercoating film having a comparatively low cost, the effect that themanufacturing cost is saved can be expected.

In addition, a state in which an operation recognition portion of atouch sensor assembly is pressed against the exterior member or thefront panel is maintained by an elastic member. Accordingly, a movementdisplacement of the exterior member or the front panel generated when auser touches the exterior member or the front panel, that is, the amountof displacement, may be accurately sensed, and there is an effect thatthe touch recognition rate of a user's touch operation is improved.

In addition, a sensor controller which processes an operation signal ofthe touch sensor assembly is separated from the touch sensor assembly,and is provided at a display assembly installed after a process in whichfoam for forming a door is foamed. Accordingly, there is an effect thatdamage of the touch sensor assembly due to static electricity generatedwhile the door is manufactured is prevented. Moreover, since a state inwhich a portion touched by a user is spaced a sufficient distance fromthe sensor controller is maintained, there is a merit that damage of thesensor controller due to static electricity generated during a touch isprevented.

In addition, since a display cover in which the touch sensor assembly isinstalled is attached to a rear surface of the front panel, and thedisplay assembly is inserted into and installed inside a door through aninsertion hole formed at a deco member, there is a merit that astructure of a front side of the door is improved.

In addition, since alignment is performed so that the display cover isinstalled at a correct position, and a light source of a display passesthrough a display window, effects that recognizability of the displaywindow is improved and the structure of the front side of the door isalso improved, can also be expected.

BRIEF DESCRIPTION OF THE DRAWINGS

Embodiments will be described in detail with reference to the followingdrawings in which like reference numerals refer to like elements, andwherein:

FIG. 1 is a front view illustrating a refrigerator according to anembodiment of the present disclosure;

FIG. 2 is a perspective view illustrating a door according to anembodiment of the present disclosure;

FIG. 3 is an exploded perspective view illustrating a shape in which adisplay assembly is installed in the door;

FIG. 4 is an exploded perspective view illustrating a shape in which afront panel of the door is separated;

FIG. 5 is an exploded perspective view illustrating a coupling structureof a touch sensor assembly and a display cover, a display assembly, adisplay frame, and a frame according to an embodiment of the presentdisclosure;

FIG. 6 is a longitudinal sectional view taken along line 6-6′ of FIG. 3;

FIG. 7 is a transversal sectional view taken along line 7-7′ of FIG. 3;

FIG. 8 is a block diagram illustrating connection between a sensorprinted circuit board (PCB) and a display PCB;

FIG. 9 is a perspective view illustrating a coupling structure of thedisplay cover and the display frame;

FIG. 10 is an exploded perspective view illustrating a couplingstructure of the display cover and the touch sensor assembly;

FIG. 11 is a perspective view illustrating the display cover in whichthe touch sensor assembly is installed, seen from behind;

FIG. 12 is a cut away perspective view taken along line 12-12′ of FIG.2;

FIG. 13 is an enlarged cross-sectional view illustrating an A portion ofFIG. 12;

FIG. 14 is an exploded perspective view illustrating a touch sensorassembly according to an embodiment of the present disclosure seen fromthe front;

FIG. 15 is an exploded perspective view illustrating the touch sensorassembly seen from behind;

FIG. 16 is a longitudinal sectional view illustrating the touch sensorassembly;

FIG. 17 is an exploded perspective view illustrating a couplingstructure of a touch sensor which constitutes the touch sensor assembly;

FIG. 18 is an enlarged view of a portion D of FIG. 17;

FIG. 19 is a cross-sectional view taken along line 19-19′ of FIG. 18;

FIG. 20 is a view illustrating various arrangements of soldering spotsaccording to an embodiment of the present disclosure;

FIG. 21 is a partial cut away perspective view illustrating a structureof the sensor PCB;

FIG. 22 is a plan view (A) and a rear view (B) illustrating a sensor PCBwhich constitutes the touch sensor assembly;

FIG. 23 is a plan view illustrating a spacer which constitutes the touchsensor assembly;

FIG. 24 is a plan view illustrating a conductive foil which constitutesthe touch sensor assembly;

FIG. 25 is a perspective view illustrating a rear surface of a touchbooster which constitutes the touch sensor assembly;

FIG. 26 is a cut away perspective view taken along line 26-26′ of FIG.2;

FIG. 27 is an enlarged view illustrating a B portion of FIG. 26;

FIG. 28 is an enlarged view illustrating a C portion of FIG. 7;

FIG. 29 is an exploded perspective view illustrating an installationprocess of the display assembly;

FIG. 30 is a flowchart illustrating a process of manufacturing a sensorPCB and attaching a touch sensor;

FIG. 31 is an exploded perspective view illustrating a structure of adisplay cover and a sensor housing according to another embodiment ofthe present invention;

FIG. 32 is an exploded perspective view illustrating a structure inwhich the touch sensor assembly according to one embodiment of thepresent disclosure is installed at a door having another type;

FIG. 33 is an exploded perspective view illustrating a structure inwhich the touch sensor assembly according to one embodiment of thepresent disclosure is installed at an air conditioner;

FIG. 34 is an exploded perspective view illustrating a structure inwhich the touch sensor assembly according to one embodiment of thepresent disclosure is installed at a washing machine;

FIG. 35 is an exploded perspective view illustrating a structure inwhich the touch sensor assembly according to one embodiment of thepresent disclosure is installed at a dishwasher; and

FIG. 36 is an exploded perspective view illustrating a structure inwhich the touch sensor assembly according to one embodiment of thepresent disclosure is installed at a cooker.

DETAILED DESCRIPTION

Embodiments of the present disclosure may be described using a touchsensor assembly installed to a door of a side by side-type refrigerator.However, the present disclosure may also be applied to other householdappliances including refrigerators to which control commands are inputby touching an exterior member thereof.

FIG. 1 is a front view illustrating a refrigerator according to anembodiment of the present disclosure. A refrigerator 1 may includecabinets forming storage spaces, and doors 10 which are installed at thecabinets, and open or close the storage space. The storage spaces may bepartitioned horizontally and/or vertically, and a plurality of doors 10which respectively open or close the storage spaces may be provided atopened front sides of the storage spaces. The doors 10 are configured toopen or close the storage spaces using a sliding or pivoting method, andare configured to form a front side exterior of the refrigerator 1 in astate in which the doors are closed.

A display window 11 (or display area) and a touch operation unit ortouch input area 12 may be provided on any one door 10 of the pluralityof doors 10. The display window 11 and the touch operation unit 12 maybe provided at a height easy to operate and recognize content orinformation shown in the display window 11.

The display window 11 is a means to show operation states of therefrigerator 1 to the outside, displays symbols or numerals when lightemitted from an inside of the door 10 transmits toward an outside of thedoor 10, and enables a user to confirm such information from theoutside.

The touch operation unit or touch input area12 may allow a user toperform a touch operation to set an operating condition of therefrigerator 1, and may be provided on a partial region of the frontsurface of the door 10. In addition, a portion or a region in which auser's push operation is sensed or allow an indication for a user toprovide touch input may be formed using a surface processing including aprinting or an etching.

Referring to FIGS. 2 to 4, the door 10 may include a front panel 20which defines a front side exterior of the door 10, deco members 40 and43 (or door trim) provided at upper and lower ends of the front panel20, and a door liner 30 which defines a rear side exterior of the door10. The front panel 20 forms the front side exterior of the door 10, andmay be formed of a stainless steel having a plate shape. The front panel20 may also be formed of a different metal, or a material having thesame look and feel a metal, or may be formed of glass or plastic asnecessary. An anti-fingerprint processing or hairline processing may befurther performed at a front surface of the front panel 20.

The display window 11 may be defined by a plurality of first throughholes 21 disposed at a partial region of the front panel 20. The displaywindow 11 may be defined as a set of the plurality of first throughholes 21 perforated at compact intervals to display numerals or symbols.For example, the set of the plurality of first through holes 21 may bedisposed in seven segments (or eighty eight segments) shape, and mayalso be formed in a specific symbol, image, pattern, or character shapewhich may show an operating condition or operation state of therefrigerator 1.

The display window 11 is formed at a position corresponding to secondthrough holes 220 and third through holes 321 (see FIG. 5) which will bedescribed below, and is formed so that light emitted from alight-emitting diode (LED) 313 of a display assembly 300 exits to theoutside of the door 10. The first through hole 21 may be formed to havea minute size using a laser processing or an etching, and may be formedto have a size which may not be recognized or visibly perceived from theoutside when the LEDs 313 do not emit light. Each of the minute holesmay have a size of 0.2 mm-0.5 mm, and each segment may include 24-36number of minute holes. As can be appreciated, the number of holes in asegment may vary based on the size of the segment desired.

Transparent sealing members 22 may be filled inside the first throughholes 21. The sealing members 22 prevent the first through holes 21 frombeing blocked by foreign materials. The sealing members 22 may be formedof a silicone or an epoxy material to fill the first through holes 21,and may be formed of a transparent material so that light passestherethrough. In addition, since the inside of the first through holes21 is filled with the sealing members 22, there is also an effect that aprocessed surface of the first through holes 21 is prevented from beingcorroded. In certain instances, the sealing members may also assist inappropriate diffusion of the light.

The sealing members 22 are filled inside the first through holes 21through a separated process, e.g., a surface coating process of thefront panel 20. Alternatively, a transparent sheet may be attached tothe front surface the front panel 20, and thus the first through holesmay be blocked from introduction of foreign materials. For example, ananti-fingerprint coating solution and/or a diffusive sheet provided atthe front surface of the front panel 20 may serve as the sealing members22.

The touch operation unit 12 is a portion or a region marked so that auser touches with fingers, and a touch sensor assembly 500 senses touchinput on the touch operation unit 12 by a user. The touch operation unit12 may be marked or formed at the front surface of the front panel 20using a surface processing such as an etching, a printing, or othersurface processing. In addition, the touch operation unit 12 may beformed in a non-protrusive shape when seen from the outside.

The door liner 30 is coupled to the front panel 20, and faces an insideof the storage space when the door 10 is closed. The door liner 30 maybe injection molded from a plastic material, and a gasket may bedisposed therealong or an installation structure for coupling of abasket or the like may be provided. In addition, when the door liner 30and the front panel 20 are coupled, a space between the door liner 30and the front panel 20 may be formed, and may be filled with a foamsolution to form a heat insulating material 24.

A frame 100 may be attached to a rear surface of the front panel 20. Theframe 100 is provided to form a separate space (interior space) insidethe door 10 in which a foam solution is not filled. The separated orinterior space formed by the frame 100 accommodates a display cover 200,the display assembly 300, the touch sensor assembly 500, a display frame400, and the like.

The deco members 40 and 43 provide a trim to define an upper side and alower side of the door 10, and cover openings formed between an upperend and a lower end of the front panel 20 and an upper end and an lowerend of the door liner 30, respectively. A hinge hole through which ahinge, which is a pivot of the door 10 passes, may be formed at an edgeof a side of the deco member 40. Wires introduced inside the frame 100through the hinge hole may extend, power may be supplied to electriccomponents inside the frame 100, and operation signals may betransmitted and received.

An insertion hole 41 is formed at a deco member 40 of the deco members40 and 43 which is coupled to the upper end of the door 10, and theinsertion hole 41 is covered by a insertion hole cover 42. The insertionhole 41 aligns with the separated or interior space defined by the frontpanel 20 and the frame 100. When the door 10 is assembled, the displayassembly 300 coupled to the display frame 400 may be inserted into theframe 100 through the insertion hole 41. The insertion hole 41 may beformed to have a size to allow the display frame 400 to be insertedthereinto, and may be positioned right above the display cover 200.

A door handle 44 may be provided at the deco member 43 coupled at thelower end of the door 10. The door handle 44 may be formed by a part ofthe deco member 43 being recessed in a pocket shape, and a user may gripthe recessed door handle 44 and pivot the door 10. A lever 45 may befurther provided at the deco member 43 of the lower end of the door 10to perform open/close operations of the door 10. Specifically, as alatch assembly 31 is driven by operating the lever 45, the door 10 maymaintain an opened or a closed state.

The display cover 200 is adhered at the rear surface of the front panel20. The display cover 200 is configured to guide installation of thedisplay assembly 300 having at least one LED 313 (see FIG. 13) mountedthereon and may be adhered at the rear surface of the front panel 20using an adhesive member 25, e.g., a double-sided tape or a primer.

The touch sensor assembly 500 senses a user's touch of the front panel20 and may be installed at a side of the display cover 200. The displaycover 200 may be attached to the front panel 20 in a state in which thetouch sensor assembly 500 is installed at the display cover 200. Whenthe display cover 200 is attached to the rear surface of the front panel20, the display window 11 formed on the front panel 20 matches thesecond through holes 220 formed in the display cover 200. In addition,the display cover 200 is accommodated in the frame 100 in a state inwhich the display cover 200 is attached to the rear surface of the frontpanel 20.

When the display assembly 300 is installed at the display frame 400, thedisplay assembly 300 may be inserted into an inner space of the frame100 through the insertion hole 41. A coupled body of the display frame400 and the display assembly 300 is inserted into an insertion spacedefined by the display cover 200. When the display frame 400 iscompletely inserted into the inside of the frame 100, the displayassembly 300 is positioned in the rear of the second through holes 220of the display cover 200. Accordingly, light emitted from the LED 313may pass the display cover 200 and the display window 11 and may beemitted toward an outside of the door 10.

Referring to FIGS. 5 to 8, a front side and an upper side of the frame100 are opened. When the frame 100 is attached to the rear surface ofthe front panel 20, an opening 110 is formed at the upper side of theframe 100. A front end of the frame 100 is bent in a direction parallelto the front panel 20, and forms a frame adhesive portion or flange 120.Specifically, the frame adhesive portion 120 adheres to the rear surfaceof the front panel 20, and is bent to have a predetermined width in adirection toward an outside of the frame 100. Since an upper end portionof the frame 100 is opened, the frame adhesive portion 120 may be formedin a U shape which connects a left side of a front side portion, a lowerside of the front side portion, and a right side of the front sideportion of the frame 100.

The adhesive member 25 formed of a double-sided tape or an adhesive maybe provided at the frame adhesive portion 120, and the frame 100 may beattached to the rear surface of the front panel 20. When the frame 100is attached to the rear surface of the front panel 20, the upper side ofthe frame 100 contacts a bottom surface of the deco member 40. Becausethe deco member 40 is provided on the upper side of the frame 100, theopening 110 of the frame 100 communicates with the insertion hole 41formed at the deco member 40.

Even though a foam solution configured to form the heat insulatingmaterial or foam 24 is introduced inside the door 10, the foam solutionis not introduced into the inner space of the frame 100. A plurality ofreinforcement ribs 130 may be formed at a rear surface of the frame 100in a grid shape or pattern. Accordingly, even though a high pressurefoam solution configured to form the heat insulating material 24 isfoamed inside the door 10, a shape of the frame 100 may not be deformedor broken due to the reinforcement rib 130, and the inner space of theframe 100 may be stably maintained.

In addition, a support plate 141 may be seated on an upper region of thefront side portion of the frame 100. To this end, plate support portions140 (or plate support) may be formed at a left edge and a right edge ofthe front side of the frame. The plate support portions 140 may beformed by parts of inner edges of the frame adhesive portion 120 beingstepped at a height corresponding to a thickness of the support plate141.

When the display cover 200 is provided inside the frame 100, the supportplate 141 is provided to cover the front side portion of the frame 100corresponding to an upper side of the display cover 200. When thesupport plate 141 is seated on the plate support portions 140, a frontsurface of the support plate 141, a front surface of the display cover200, and the frame adhesive portion 120 are formed on the same plane.When the frame 100 is attached to the rear surface of the front panel20, a phenomenon in which the frame 100 is shaken or is not firmlyattached to the front panel 20 because of a height difference betweenthe support plate 141 and a front side portion of the display cover 200may be prevented. In addition, a portion of the front panel 20 in whicha height difference is generated is prevented from being deformed by animpact from the outside.

The plate support portions 140 are configured to support left and rightends of the support plate 141. When the frame 100 is attached to thefront panel 20, the support plate 141 may slide and be inserted into aspace formed between the plate support portion 140 and the rear surfaceof the front panel 20. In addition, the support plate 141 may also beattached to the rear surface of the front panel 20 with the frame 100 ina state in which the support plate 141 is fixed to the plate supportportion 140.

A wire inlet hole 150 may be formed at an upper portion or region of aside of the frame 100. The wire inlet hole 150 forms a path to allowpassage of wires connecting electric components provided inside theframe 100 and a power components of the cabinet. As the wire inlet hole150 is formed at an upper portion of the side thereof adjacent to ahinge of the door 10, a distance between the wire inlet hole 150 and ahinge hole of the door 10 may be minimized. Before the wires aredisposed through the wire inlet hole 150 and a foam solution is foamedinside the door 10, a finishing process which covers the wire inlet hole150 is performed, and thus a foam solution is prevented from beingintroduced into the frame 100.

Restraint or restriction grooves 160 may be respectively formed at leftand right sides of the frame 100. The restraint grooves 160 are portionsinto which restraint portions or rail guide 230 which protrude in awidthwise direction of the display cover 200 from both side ends of thedisplay cover 200 are respectively inserted. As the restraint groove 160is formed to be recessed in a shape corresponding to that of therestraint portion 230, the display cover 200 is not shaken in a state inwhich the display cover 200 is accommodated in the frame 100, andmaintains a correct position.

Cover support portions 170 (or cover support) support the display cover200 and may be formed to protrude at side surfaces corresponding tolower sides of the restraint grooves 160 of inner surfaces of the frame100. The displace cover 200 is provided in the inner space of the frame100 below the lower sides of the restraint grooves 160. The coversupport portions 170 protrude from left and right side surfaces of theframe 100 toward a center of the frame 100, and push to support bothside ends at a rear surface of the display cover 200.

When the frame 100 is attached to the front panel 20 and a foam solutionis foamed inside the door 10, the display cover 200 is attached to therear surface of the front panel 20, and the cover support portions 170push forward the display cover 200 to maintain the display cover 200attached to the front panel 20. The adhesive member 25 adheres thedisplay cover 200 to the rear surface of the front panel 20, but whenthe adhesive member hardens and loses its adhesiveness, the displaycover 200 is pressed against the rear surface of the front panel 20 by aforce of the cover support portions 170 pressing against the displaycover 200.

A plurality of cover support portions 170 may be vertically provided atpredetermined intervals, and evenly push and support the entire rearsurface of the display cover 200. In addition, one or a plurality ofprotrusive portions 171 (or bumps) may be further formed at frontsurfaces of the cover support portions 170 which contact the rearsurface of the display cover 200. The protrusive portion 171 may beformed in a rib shape formed in a lengthwise direction or in aprotrusive shape having a hemisphere shape, and may be in line or pointcontact with the display cover 200. Accordingly, even though contactsurfaces between the display cover 200 and the cover support portions170 are not even, the display cover 200 may not incline. In addition,the cover support portions 170 may transmit even pressure to the displaycover 200.

For example, when the display cover 200 is obliquely inclined forward orbackward and is pressed against the rear surface of the front panel 20,the frame 100 may be pressed by a foam solution. While the protrusiveportions 171 which press the surfaces of the display cover 200corresponding to a side comparatively far away from the front panel 20are worn down by pressure of the foam solution, the display cover 200may be aligned at a right position.

The display cover 200 may be formed of a plate-shaped plastic material,and may be provided in the frame 100 where the display cover 200 isattached to the front panel 20. An accommodation portion or opening 210at which the touch sensor assembly 500 is installed is formed at thedisplay cover 200. After assembly, the plurality of second through holes220 may be formed at the display cover 200 of a position/locationcorresponding to the display window 11.

The display assembly 300 may include a display PCB 310 on which the LED313 is mounted, and a reflector 320 disposed at a front surface of thedisplay PCB 310. An LED controller configured to drive the LED 313, anda sensor controller 330 configured to drive the touch sensor assembly500 may be mounted on the display PCB 310. The sensor controller 330processes touch signals of the front panel 20 sensed through the touchsensor assembly 500 using the display PCB 310. As illustrated in FIG. 8,a sensor PCB 700 and the display PCB 310 which constitute the touchsensor assembly 500 may be connected using a cable connector 600.

The cable connector 600 may include a first cable connector 610connected to the sensor PCB 700, and a second cable connector 620connected to the display PCB 310. Terminals may be formed at endportions of the first cable connector 610 and the second cable connector620 to electrically connect them.

While the display assembly 300 is installed at the door 10, the firstcable connector 610 and the second cable connector 620 may extend tohave a length to connect each other at the outside of the door 10. Whenthe display cover 200 is attached to the rear surface of the front panel20, the first cable connector 610 may be formed at least longer than adistance from an upper end of the touch sensor assembly 500 to theinsertion hole 41. When the touch sensor assembly 500 is installed atthe display cover 200, the cable connectors 610 and 620 are connected atan outside of the insertion hole 41, and the display assembly 300 isinserted and installed at an inside of the insertion hole 41.

A display terminal 311 connected to the second cable connector 620 maybe disposed at a left side of an upper end of the display PCB 310 (seenfrom FIG. 5). As the display terminal 311 is disposed at a position asfar away from the touch sensor assembly 500 as possible to minimize apossibility of static electricity generated when a user's finger touchesthe front panel 20 is transmitted to the display PCB 310. Thepossibility in which the static electricity is transmitted to thedisplay PCB 310, and components mounted on the display PCB 310 areelectrically damaged is minimized.

The reflector 320 attached to the front surface of the display PCB 310guides light emitted by the LED 313 to focus on the first through holes21. The reflector 320 not only guides the light emitted by the LED 313but also enables the display PCB 310 and the display terminal 311 to bespaced a distance corresponding to a thickness of the reflector 320 fromthe rear surface of the front panel 20, and protects the display PCB 310from static electricity.

Because the front panel 20 is formed of a stainless steel and thedisplay assembly 300 is provided to be adjacent to the display window11, the front panel 20 may be vulnerable to static electricity generatedwhen a user touches the touch operation unit 12. As the reflector 320 isprovided at the front surface of the display PCB 310, the display PCB310 is structurally spaced apart from the front panel 20. The reflector320 simultaneously improves transmission of light and protects thedisplay PCB 310 from static electricity.

The third through holes 321 are formed at the reflector, andlocation/position of the holes 321 corresponds to an arrangement of theLED 313 to allow communication with the second through holes 220 and thefirst through holes 21. When the display assembly 300 is installed atthe display frame 400, and the display frame 400 is installed at thedisplay cover 200, the first through holes 21, the second through holes220, and the third through holes 321 are pressed forward or backwardagainst each other and communicate with each other. Accordingly, lightemitted by the LED 313 passes through the first to the third throughholes 21, 220, and 321 and is emitted to the outside of the door 10through the display window 11.

An audio output unit or component 340 may be provided at a rear surfaceof the display PCB 310. The audio output unit 340 may be configured toprovide an audio output, e.g., sound, indicative of an operation stateof the refrigerator 1, and may be an actuator, a speaker, a buzzer, andthe like. The audio output unit 340 may be inserted into a frame hole412 formed in the display frame 400. Accordingly, a sound output fromthe audio output unit 340 is transmitted to a user located in front ofthe door 10, and the user may recognize the operation state or a drivingstate of the refrigerator 1.

The display frame 400, in which the display assembly 300 including thedisplay PCB 310 is installed, may have a plate shape so that the displayPCB 310 can be seated. A space to accommodate the display PCB 310 isdefined at a front side of the display frame 400 by an edge 410 whichextends along an edge of the display frame 400 and protrudes forwardfrom the display frame 400. In addition, a sliding insertion portion orrail 415 may be formed at a front end of the edge 410 at left and rightedges of the display frame 400. The sliding insertion portion 415 isformed in a shape of rib bent in a direction perpendicular to the edge410, i.e., in a widthwise direction of the display frame 400.

When the display frame 400 is coupled to the display cover 200, thesliding insertion portion 415 is inserted into an inside of a rail guide240 formed at the display cover 200. Accordingly, the display frame 400may be smoothly inserted into the display cover 200 by the slidinginsertion portion 415.

A reinforcement rib 411 vertically and horizontally extending atpredetermined intervals to form a grid may be provided at the entirefront side of the display frame 400. A frame cut portion or a frame cutout 414 may be formed at an upper end of the display frame 400. As theframe cut portion 414 is cut at a position corresponding to the displayterminal 311, interference between the display terminal 311 and thedisplay frame 400 may be prevented.

In addition, bosses 413 may protrude at the front side of the displayframe 400, and screws 312 are fastened into the bosses 414 to fix thedisplay PCB 310 to the display frame 400. Due to the protrusion of thebosses 413, the display PCB 310 is spaced a prescribed distancecorresponding to a protrusion height of the bosses 413 from the frontside of the display frame 400.

A frame handle 420 may extend upward at a central location of the upperend of the display frame 400. The frame handle 420 allows a user tomanipulate the display frame 400 for insertion into the display cover200. The frame handle 420 includes a first vertical portion or rod/shaft421 which extends from the display frame 400, a inclined portion orrod/shaft 422 which inclines backward from an upper end of the firstvertical portion 421, and a second vertical portion or rod/shaft 423which extends upward from an upper end the inclined portion 422.

The first vertical portion 421 and the second vertical portion 423extend in parallel each other, and connected by the inclined portion422. A grip portion or grip handle 424 extends in a horizontal directionat an upper end of the second vertical portion 423.

Accordingly, the user may grip the grip portion 424 to insert thedisplay frame 400 from the lower end of the display frame 400 into aninside of the insertion hole 41 and into the display cover 200. Due tothe structure of the frame handle 420, the display frame 400 may beincreasingly pressed against the rear surface of the display cover 200as the display frame 400 is increasingly inserted downward.

When the display frame 400 is completely inserted into an inside of thedisplay cover 200, and the insertion hole cover 42 is installed at theinsertion hole 41, a bottom surface of the insertion hole cover 42 maycontact a top surface of the grip portion 424. In order to allowcoupling between the grip portion 424 and the cover 42, a bottom surfaceof the insertion hole cover 42 may be contoured to have a negativerelief of grip portion 424. When the insertion hole cover 42 is providedover the insertion hole 41, an upper end of the frame handle 420 may becoupled via the negative relief at the bottom surface of the cover 42 tomaintain a fixed state.

Referring to FIGS. 9 to 11, the rail guide 240 is formed at left andright sides of the display cover 200. If the display cover 200 is madefrom a bendable material, e.g., metallic, the rail guide 240 may beformed at both ends of the display cover 200 by bending the ends aplurality of times, and the sliding insertion portion 415 is insertedinto the inside of the display cover 200 along the guide rail 240.

As illustrated in FIG. 11, a forward and backward width (groovethickness) at an upper end of the rail guide 240 is greater than aforward and backward width at a lower end portion to facilitateinsertion of the sliding insertion portion 415. In addition, a rear sideof the rail guide 240 is inclined in a direction toward the frontsurface of the display cover 200 such that the groove width decreasestoward a lower portion of the rail guide 240.

As the display frame 400 is increasingly inserted into the display cover200, the display assembly 300 at a front surface of the display frame400 is increasingly pressed against the display cover 200. When thedisplay frame 400 is completely inserted into the display cover 200, thesliding insertion portion 415 is fixed to an inside of the rail guide240, and the reflector 320 is completely pressed against the rearsurface of the display cover 200. Further, the third through holes 321are aligned forward and backward with the second through holes 220.

The front surface of the display cover 200 is attached or fixed to therear surface of the front panel 20, and the accommodation portion 210 isformed at a side of the front surface of the display cover 200 toaccommodate the touch sensor assembly 500. The accommodation portion 210may be an opening having a shape corresponding to a shape of the touchsensor assembly 500, and the touch sensor assembly 500 is insertedtherein. When the touch sensor assembly 500 is installed at theaccommodation portion 210, a front surface of the touch sensor assembly500 and the front surface of the display cover 200 are on the sameplane, i.e., the front surfaces are flush with each other.

Housing support portions or housing supports 211 a and 211 b may beformed to extend backward or rearward from the display cover 200 todefine the opening of the accommodation portion 210. At the four cornersof the opening, the housing support portions 211 b extend in an “L”shape from the four corners of the accommodation portion 210. Thehousing support portions 211 a support the side of the touch sensorassembly, and housing support portions 211 b support the side corners ofthe touch sensor assembly 500. In addition, an end 211 c of the housingsupport portion 211 may be bent to press against a rear surface of thetouch sensor assembly 500. The sides, corners and the rear surfaces ofthe touch sensor assembly 500 are supported by the housing supportportion 211 a, 211 b and 211 c (hereinafter collectively referred to as“211”). Even when a user touches the front panel 20, and the frontsurface of the touch sensor assembly 500 is pressed, the touch sensorassembly 500 is not moved backward, and an initially assembled state ismaintained.

Housing coupling portions or couplers 511 formed at an upper and a lowerends of a sensor housing 500 a (see FIG. 14) clip into upper and loweredges of the accommodation portion 210, and at least one of the housingcoupling portions 511 formed at the upper and the lower ends of thesensor housing 500 a has a hook shape. When the touch sensor assembly500 is inserted into the inside of the accommodation portion 210 from afront of the display cover 200, the housing coupling portions 511 cliponto an edge of the accommodation portion 210 such that the touch sensorassembly 500 is fixed and coupled to the display cover 200.

When the display cover 200 is attached to the rear surface of the frontpanel, the second through holes 220 formed at the front surface of thedisplay cover 200 are aligned forward and backward with the firstthrough holes 21. The second through holes 220 may also be opened in ashape corresponding to the seven segments (or eighty eight segments),and may also be formed in a shape of a plurality of simple holes to showother information.

Block portions or trims 221 may be formed at edges of the second throughholes 220. The block portions 221 may protrude from the edges of thesecond through holes 220 toward a front of the display cover 200. Theadhesive member 25 is provided at the front surface of the display cover200, and may be coated or attached to only an external region of theblock portions 221. When the display cover 200 is attached to the rearsurface of the front panel 20, a gap size between the first through hole21 and the second through hole 220 may be minimized by the thickness ofthe adhesive member 25 such that the leakage of light through the gapmay be minimized. The block portions 221 may have a height, whicheffectively prevents light leakage. Based on the adhesive member 25 onthe front surface of display cover 200 is compressed by pressure of thefoam solution solidifying inside the door 10, the block portions 221 mayprotrude at a height less than a height before the adhesive member 25 iscompressed.

Referring to FIGS. 12 and 13, the first through hole 21 and the secondthrough hole 220 are communicated with each other when the display cover200 is attached to the rear surface of the front panel 20 by theadhesive member 25. Because a size of each of the first through holes 21may be substantially less than that of the second through hole 220, aplurality of the first through holes 21 may be provided in an innerregion of a single second through hole 220.

When the display frame 400 is completely inserted into the display cover200 and the display assembly 300 is positioned at the inside of thedisplay cover 200, the third through holes 321 are aligned forward andbackward with the second through holes 220. Sizes and shapes of thesecond through hole 220 and the third through hole 321 are the same, andas the reflector 320 is pressed against the rear surface of the displaycover 200, the third through holes 321 may be accurately aligneddirectly behind the second through holes 220. As the first to the thirdthrough holes 21, 220 and 321 communicate with each other from front toback, light emitted by the LED 313 may sequentially pass the thirdthrough holes 321, the second through holes 220, and the first throughholes 21, and may be emitted to the outside of the door 10.

A diffusive or diffusion sheet 26 may be attached at the rear surface ofthe front panel 20 corresponding to a region or an area in which thefirst through holes 21 are formed. The diffusive sheet 26 may diffuselight emitted by the LED 313, and the light emitted through the displaywindow 11 may evenly light the entire display window 11. In addition,when the diffusive sheet 26 is attached to the rear surface of the frontpanel 20 corresponding to a region of the display window 11, thediffusive sheet 26 also additionally performs a function to cover all ofthe first through holes 21 such that an additional coating on the frontsurface of the front panel 20 may not be necessary, as described above.

Referring to FIGS. 14 and 15, the touch sensor assembly 500 may includethe sensor housing 500 a forming the exterior of the touch sensorassembly 500, the sensor PCB 700 accommodated in an inside of the sensorhousing 500 a, an elastic member or support 720 to support the sensorPCB 700, and a touch booster or touch transfer plate 530 coupled to anopening 512 formed at a front side of the sensor housing 500 a.

The sensor housing 500 a includes a housing cover 510 and a housing body520, and a space to house the sensor PCB 700 formed by the housing cover510 and the housing body 520 being coupled to each other. The housingcover 510 may define a front and side surfaces of the touch sensorassembly 500, and the housing body 520 may define the rear surface ofthe touch sensor assembly 500. In addition, side surfaces of the housingbody 520 and side surfaces of the housing cover 510 are overlapped.

The housing cover 510 forms the front surface, left and right surfaces,and top and bottom surfaces of the sensor housing 500 a, and the housingcoupling portion 511 are formed at the top and bottom surfaces of thehousing cover 510. The housing coupling portion 511, as described above,enables the touch sensor assembly 500 to be fixed and installed at theaccommodation portion of the display cover 200. When the touch sensorassembly 500 is installed at the accommodation portion 210, a frontsurface of the housing cover 510 may be exposed to an outside of thedisplay cover 200 and attached to the rear surface of the front panel 20by the adhesive member 25.

The opening 512 is formed at the front surface of the housing cover 510,and the touch booster 530 is installed at the opening 512. The touchbooster 530 is configured to allow transmission a spatial displacement(the amount of displacement) of the front panel 20 which is generatedwhen a user touches and pushes the front panel 20 for detection of theuser's touch input by sensors 750, which will be described hereinafter.

The opening 512 is formed to have a size and a shape corresponding tothose of the touch booster 530, and the opening 512 is covered by thetouch booster 530. An extending rib 517 is formed to extend backwardfrom the housing cover 510 at an edge of the opening 512, and is pressedagainst a side surface of the touch booster 530. As the side surface ofthe touch booster 530 is pressed against an inner circumferentialsurface of the extending rib 517 and the touch booster 530 moves forwardor backward due to touch pressure, inclination or shaking/rattling in aleft and right direction is prevented.

In addition, booster support portions or booster support plates 513 maybe respectively formed at left and right inner circumferential surfacesof the opening 512. Specifically, the booster support portions 513protrude from the extending rib 517 toward a center of the opening 512,and extend along the inner circumferential surfaces of the extending rib517.

The booster support portions 513 may extend from a position spaced apredetermined distance behind a front end portion of the extending rib517 toward a rear of the housing cover 510 to a predetermined width. Adistance between a front end portion of the extending rib 517 and afront end portion of the booster support portion 513 may be actuallyslightly less than a thickness of the touch booster 530. The thicknessdifference may correspond to the thickness of the adhesive member 25attached to the display cover 200 such that the touch booster 530contacts the rear surface of the front panel 20. In other words, a ledgeis formed by the extending ribs 517 and the booster support portions513, and the thickness of the ledge in the forward and rearwarddirection is less than the thickness of the touch booster 530. Thebooster support portion 513 supports left and right edges of a rearsurface of the touch booster 530 when the touch booster 530 is installedthereat. Even though touch pressure is applied to a front surface of thetouch booster 530 to cause spatial displacement, the touch booster 530is prevented from moving backward past a predetermined position.

Hook grooves 514 are formed at the booster support portion 513, and thehook grooves 514 accommodate hooks or clips 531 formed at the touchbooster 530. A space between two adjacent booster support portions 513define each hook groove 514, and when the touch booster 530 is installedat the opening 512, the hooks 531 formed at the touch booster 530 passthrough the hook grooves 514.

When the touch booster 530 is installed into the housing cover 510, endportions of the hook 531 are hooked on end portions of the extending rib517. In this state, when the touch booster 530 moves backward by a touchpressure, the end portions of the hook 531 are separated from a rear endof the extending rib 517, and are pressed forward thereagainst again bythe elastic member 720 upon release of the touch pressure, describedhereinafter. A forward and backward movement distance of the touchbooster 530 may be very small. When the touch booster 530 moves forwardor backward, the hook grooves 514 prevent the touch booster 530 frombeing vertically shifted. The touch booster 530 may move a minutedistance forward or backward by touch pressure.

As described above, the front surface of the touch booster 530 mayprotrude forward slightly more than the housing cover 510. When thetouch sensor assembly 500 and the display cover 200 are attached to therear surface of the front panel 20, the touch booster 530 is firmlypressed against the rear surface of the front panel 20 (See across-sectional view of FIG. 24). Accordingly, minute touch pressureapplied to the front surface of the front panel 20 may be transmitted tothe touch booster 530.

Cover coupling portions or grooves 516 may be formed at a side surfaceof the housing cover 510. The cover coupling portions 516 are grooves inwhich body coupling portions or clips 521 formed at the housing body 520are inserted. The grooves have a hole shape so that the body couplingportions 521 having a hook shape are hanged or clipped thereinto toallow coupling between the housing body 520 and the housing cover 510.

Further, the cover coupling portions 516 can be formed at positions toallow uniform compression of a plurality of elastic members 720 providedat the sensor PCB 700 such that the sensor PCB 700 and the touch booster530 are uniformly pushed forward. The positions of the cover couplingportions 516 and the body coupling portions 521 may be positionedbetween the elastic members 720 positioned at upper and lower ends ofthe sensor 750 (see FIG. 16). Because the touch booster 530 is firmlypressed against the front panel 20 based on the touch booster 530protruding slightly forward from the front surface of the housing cover510, the touch booster 530 may effectively sense touch pressure when auser touches the front surface of the front panel 20. A structure and afunction of the sensor PCB 700 and the elastic member 720 will bedescribed in detail hereinafter.

A wire hole 515 may be formed at a top surface of the housing cover 510.The wire hole 515 is opened so that the first cable connector 610connected to a sensor terminal 711 installed at the sensor PCB 700 topass through. The wire hole 515 may be formed at at least one side ofthe housing cover 510 and the housing body 520. Further, a wire hole 522may be formed at an upper side of the housing body 520. The wire hole522 may be formed at the same position of the wire hole 515 of thehousing cover 510, and may be formed so that the first cable connector610 passes through. As can be appreciated, both wire holes 515 and 522may not be required as long as at least one hole is provided in eitherthe housing cover 510 or housing body 520.

The housing body 520 coupled to the housing cover 510 forms an exteriorof the touch sensor assembly 500, and forms a space in which the sensorPCB 700 is installed. The housing body 520 may be formed with a rearsurface and sides, which extend forward from four edges of the rearsurface. The plurality of body coupling portions 521 may be formed atside surfaces of the housing body 520. The body coupling portions 521may be formed by a part of a side portion of the housing body 520 beingcut. Alternatively, the touch booster 530, housing cover 510 and thehousing body 520 may be injection molded.

The plurality of cover coupling portions 516 and the body couplingportions 521 may be disposed at equal intervals in a lengthwisedirection of the touch sensor assembly 500. In addition, left covercoupling portions 516 and right cover coupling portions 516 are formedat the same heights, which is also similar to the plurality of bodycoupling portions 521. Accordingly, when the housing cover 510 iscoupled to the housing body 520 the elastic members 720 may be preventedfrom being inclined in one direction while the touch sensor assembly 500is assembled since the same or substantially the same force is appliedto the elastic members 720.

An installation guide 523 may be formed at a rear side portion (or abottom surface) of the housing body 520. A surface in which theinstallation guide 523 is formed may be defined as the rear surface whenthe housing body 520 is oriented in a vertical orientation, and may bedefined as the bottom surface when the housing body 520 lies on ahorizontal surface. The installation guide 523 guides installation ofthe plurality of elastic members 720, and defines a space configured toaccommodate the elastic members 720 attached to the sensor PCB 700.

The installation guide 523 may be formed in a shape corresponding to thesensor PCB 700. A horizontal width of the sensor PCB 700 may be greaterthan that of an inner space formed by the installation guide 523. Thehorizontal width of the inner space formed by the installation guide 523may be equal to or slightly greater than a horizontal width of theelastic member 720. The elastic member 720 may be positioned at an innerregion of the installation guide 523, and left and right surfaces of theinstallation guide 523 respectively support left and right surfaces ofthe elastic member 720. When the elastic members 720 are compressed by auser's touch pressure, the elastic member 720 is prevented from beingtwisted or inclined in one direction, and the sensor PCB 700 may bestably supported.

A terminal hole or opening 524 may be formed at a rear surface of thehousing body 520 and a location of the terminal hole corresponds to aposition of the sensor terminal 711 provided at the sensor PCB 70. Theterminal hole 524 is formed to have a size corresponding to the sensorterminal 711, i.e., equal to or slightly greater than that of the sensorterminal 711, so that the sensor terminal 711 is exposed behind thehousing body 520 through the terminal hole 524. When the sensor PCB 700is shaken forward or backward, the sensor terminal 711 does notinterfere with the rear surface of the housing body 520. Further, thefirst cable connector 610 is coupled to a side surface of the sensorterminal 711, and when a horizontal width of the terminal hole 524 isslightly greater than a horizontal width of the sensor terminal 711, acoupling state of the first cable connector 610 and the sensor terminal711 may be confirmed through the terminal hole 524.

The sensor PCB 700 may include a spacer 730, the sensor 750, and aconductive foil 740, and may be supported by the elastic member 720inside the sensor housing 500 a. In addition, the touch booster 530 isinstalled at the opening 512 directly behind the front panel 20 to moveforward or backward. A contact between the touch booster 530 and thefront panel 20 may be continuously maintained such that a forward andbackward movement displacement of the front panel 20 generated when auser touches the touch operation unit 12 of the front panel 20 may beimmediately transmitted to the sensor 750.

Referring to FIGS. 16 and 17, the sensor PCB 700 may be formed of aplastic material. A copper coating or film 712 (a conductive layer) isused to print a circuit on a front surface (a top surface in thedrawing) of an insulating substrate of the sensor PCB 700. The sensor750 for sensing a movement or spatial displacement of the front panel 20based on a user's touch input is provided at the front surface of thesensor PCB 700. As can be appreciated, other electrically conductivematerial may be used instead of the copper coating or film.

The sensor 750 may be a piezo sensor, and may include a metal plate 751,and a ceramic element or disc 752 attached on a front surface of themetal plate or disc 751 (a top surface in the drawing). The metal plate751 is elastically deformed by touch pressure generated when a usertouches the front surface of the front panel 20. The ceramic element 752generates electricity based on the touch pressure. The piezo sensor is apressure sensing sensor known to one of ordinary skill in the art, and adetailed description regarding the principle of the piezo sensor isomitted. Although the sensor 750 having a circular shape is exemplified,the sensor 750 may not be limited to the circular shape, and may beformed to have other shapes.

The sensor 750 may be formed in plural number according to the sensorPCB 700, and a sensor support portion 713 may be formed at the frontsurface of the sensor PCB 700 in which the sensor 750 is installed. Thesensor support portion 713 may be defined as a groove or hole having asize (or a diameter) less than that of the sensor 750 (or a circularshaped sensor). Accordingly, an edge of a rear surface (or a bottomsurface) of the metal plate 751 of the sensor 750 is supported by anedge of a front surface (or a top surface) of the sensor support portion713. The sensor support portion 713 protrudes in a boss shape whoseinside may be empty, that is, not a groove or hole shape, and the sensor750 may be positioned at a top surface of the boss.

When the sensor support portion 713 and the sensor 750 have a circularshape, a diameter of the sensor support portion 713 may be formed to beless than that of the metal plate 751, and may be formed greater thanthat of the ceramic element 752. Accordingly, the metal plate 751 may bedeformed by touch pressure applied to the front panel 20, and theceramic element 752 may effectively sense a change of pressure appliedto the sensor 750.

In addition, a horizontal plane which passes the center of a pluralitythe sensors 750 and a horizontal plane which bisects the body couplingportion 521 and a cover coupling portion 516 may be coplanar. In otherwords, as shown in FIG. 14, the body coupling portion 521 and the covercoupling portion 516 may be bisected by a horizontal plane which passesthe center of the sensor 750. Thus, a uniform pressure is applied to theentire sensor PCB 700 positioned inside the sensor housing 500 a, andall of the plurality sensors 750 may be able to sense a user's operationsignal under the same condition.

When the sensor support portion 713 is a hole passing through the coppercoating or film and the insulating substrate rather than a groove whichdoes not go through the insulating substrate, a cover member or a filmcover 770 may be attached onto a rear surface of the sensor PCB 700 onwhich the sensor support portion 713 is formed. As the cover member 770is formed to be larger than the sensor support portion 713, the covermember 770 may completely cover an opened rear surface of the sensorsupport portion 713. According to the above-described structure, a frontsurface and the rear surface of the hole-shaped sensor support portion713 are respectively covered by the touch sensor 750 and the covermember 770.

As the cover member 770 is completely adhered to the rear surface of thesensor PCB 700 by an adhesive, airtightness inside the sensor supportportion 713 may be maintained. Accordingly, the cover member 770 mayprevent moisture from penetrating inside the sensor support portion 713,and may prevent corrosion of the touch sensor 750.

A spacer 730 and a conductive foil 740 which will be described below aresequentially attached onto a top surface of the sensor PCB 700. A sensorhole 731 which accommodates the touch sensor 750 is formed in the spacer730, and the spacer 730 is covered by the conductive foil 740, i.e., thesensor hole 731 is covered by the conductive foil 740. When the housingbody 520 and the housing cover 510 are coupled to each other, the touchbooster 530 installed at the housing cover 510 is in contact with theconductive foil 740. The touch booster 530 may press the touch sensor750 according to an operation of touching the touch operation unit 12 bya user.

The touch sensor 750 is mounted on a sensor mounting portion or a sensormounting surface 718, which is not covered by the spacer 730 to exposethe copper coating or film 712. The sensor mounting portion 718 may beformed as a ledge formed by an edge of the sensor hole 731 at the spacer730 and an edge of the sensor support portion 713 formed at the sensorPCB 700. According to the above-described structure, a bottom surface ofthe metal plate 751 of the sensor 750 is in direct contact with thecopper coating or film 712 and is electrically connected thereto.

When the touch sensor 750 is shifted from a correct attachment positionand is mounted on the sensor PCB 700 misaligned, the recognition rate ofa touch operation or electrical conductivity is decreased, and thus, atouch signal may not be transferred normally. In addition, when thetouch sensor 750 is fixed on the sensor PCB 700 using a conventionalsoldering method, the touch sensor 750 having a very small and sensitivepiezo-type may be damaged. Since the touch sensor 750 is inclined or aheight difference occurs by a soldering, and as a result, thesensitivity of the touch sensor 750 is decreased and the touch sensor750 substantially cannot be applied.

Even though the touch sensor 750 may be adhered to the sensor PCB 700using an adhesive to fix the touch sensor 750, such a process cannot beperformed automatically and must rely on a manual operation or accuracyof worker, and thus, it is difficult to expect the uniform reliabilitythereof. When an applied adhesive is thick, the touch sensor 750 may beinclined, and electrical conductivity between the touch sensor 750 and acoating film is decreased. However, when an applied adhesive is thin,there is a problem that the adhesive force is weak and the touch sensor750 may move or shift from a correct position. In order to improveelectrical conductivity, a film having high electrical conductivity mustbe used, and in this case, manufacturing costs rise.

In order to possibly prevent the above problems, soldering spot 715 isformed by printing a solder cream at a position on the sensor mountingportion 718 to stably fix the touch sensor 750 and to preventinclination or damage of the touch sensor 750. The solder cream in apaste or cream form made by uniformly mixing solder powder, tin powder,and a special solvent may be applied to a sensor mounting portion of thetouch sensor using a printing method.

Referring to FIGS. 18 and 19, the sensor mounting portion 718 is formedby an exposed top surface of the copper coating or film 712 at thesensor PCB 700. A top layer or a protective layer 716 may be furtherprinted on a top surface of the copper coating or film 712 to protectthe copper coating or film 712. The top layer 716 may be also applied tothe top surface of the copper coating or film 712 except a regioncorresponding to the sensor hole 731 of the spacer 730.

The sensor mounting portion 718 may be a portion exposed through thesensor hole 731 of the spacer 730, the touch sensor 750 may be installedthereat, and the sensor mounting portion 718 may be electricallyconnected to the touch sensor 750. As illustrated in the drawing, adiameter of the sensor mounting portion 718 may be greater than adiameter of the metal plate 751 of the sensor 750. In addition, thediameter of the sensor mounting portion 718 may be the same as adiameter of the sensor hole 731 formed in the spacer 730.

The soldering spot or solder contact point 715 is formed at one side ofthe sensor mounting portion 718. The soldering spot 715 is formed by asolder cream being applied, is formed at the sensor mounting portion 718using a printing method, and is formed at a region in contact with abottom surface of the metal plate 751 which constitutes the touch sensor750. The solder cream may be thinly applied so that the touch sensor 750is not inclined. The solder cream may be formed at one position in aspot shape so that the touch sensor 750 is fixed to the sensor mountingportion 718 before the conductive foil 740 is attached thereto.

When the touch sensor 750 is attached to the sensor PCB 700, the metalplate 751 of the touch sensor 750 is mounted on the sensor mountingportion 718 and presses the solder cream. As a result, the solder creamis spread between the bottom surface of the metal plate 751 and a topsurface of the sensor mounting portion 718, and forms the soldering spot715. In addition, when a heating process is preformed, the touch sensor750 is fixed to the sensor PCB 700 by the soldering spot 715.

According to the above-described fixing method, only one position of themetal plate 751 of the touch sensor 750 corresponding to across-sectional area of the soldering spot 715 is fixed to the sensorPCB 700. Since there is no influence on overall tension of the touchsensor 750 including the ceramic element 752 which actually senses auser's touch, a user's touch operation may be correctly and uniformlysensed. The soldering spot 715 may be formed at one position on thesensor mounting portion 718, and other various shapes of arrangement maybe used.

FIG. 20 is a view illustrating samples of various arrangements ofsoldering spots according to an embodiment of the present disclosure.

Referring to (a) of FIG. 20, the soldering spot 715 may be formed at oneposition on the sensor mounting portion 718. In addition, when only oneof the soldering spot 715 is formed, a position thereof may be variouslyselected on the sensor mounting portion 718.

Referring to (b) of FIG. 20, the soldering spots 715 may be formed attwo positions on the sensor mounting portion 718. As the soldering spots715 are disposed adjacent to each other, it may be similar to the casein which the soldering spot 715 is formed at one position, and it mayfurther improve a fixing force than the case in which the soldering spot715 is formed at one position.

Referring to (c) of FIG. 20, the soldering spots 715 may be formed attwo positions, and the two soldering spots 715 may have an angle of 90°to each other relative to the center of the sensor support portion 713.

Referring to (d) of FIG. 20, the soldering spots 715 may be formed attwo positions, and the two soldering spots 715 may have an angle of 180°to each other relative to the center of the sensor support portion 713.The two soldering spots 715 may be positioned at positions facing eachother based on the sensor support portion 713, and may fix the touchsensor 750. Since forces applied to the soldering spots 715 aresymmetrical with respect to the sensor support portion 713, the touchsensor 750 may be firmly and stably fixed and supported than othercases.

Referring to (e) of FIG. 20, three soldering spots 715 may be formed.The three soldering spots 715 may be disposed to be opened at a 120°from each other along a circumferential surface of the sensor supportportion 713. Thus, the touch sensor 750 may be further firmly and stablyfixed by the soldering spots 715.

When more than four soldering spots 715 are formed at the sensormounting portion 718, the touch sensor 750 may be further stably fixedto the sensor PCB 700. However, there may be a negative influence on atension of the touch sensor 750, and the recognition rate of the touchsensor 750 may be decreased. Since it is sufficient that a temporalfixed state of the touch sensor 750 is maintained before the touchsensor 750 is covered by the conductive foil 740 and fixed thereto, morethan four soldering spots 715 are not necessary.

FIG. 21 is a partial cut away perspective view illustrating a structureof the sensor PCB, and FIG. 22 is a plan view (A) and a rear view (B)illustrating a sensor PCB which constitutes the touch sensor assembly.The sensor PCB 700 may include an insulating substrate 717 of a resinmaterial, the copper coating or film 712 coated on a top surface of theinsulating substrate 717 with a copper material, and a top layer 716printed on the top surface of the copper coating or film 712.

The insulating substrate 717 forms a base of the sensor PCB 700, and maybe an epoxy resin material and/or reinforcement material such as paperor fiber glass. The copper coating or film 712 is forms the signal line,and is formed by coating a copper material generally used for a PCB. Acircuit is printed and processed thereon.

The top layer 716 may be printed or coated to protect the copper coatingor film 712 from oxidation corrosion of the copper coating or film 712and external factors, and may be printed or coated using a resinmaterial. As the top layer 716 is printed or coated on the top surfaceof the copper coating or film 712 except the sensor mounting portion718, in which the touch sensor 750 is installed, the sensor mountingportion 718 is exposed to the outside. When the sensor PCB 700 iscompletely formed, only the sensor mounting portion 718, which is a partof the copper coating or film 712, is exposed to the outside. Thesoldering spot 715 may be formed at the sensor mounting portion 718, andthe metal plate 751 of the touch sensor 750 may be mounted on the sensormounting portion 718.

A common contact point or common pad 714 connected by positiveelectrodes of a plurality of sensors 750 and the circuit is formed atone side of the sensor PCB 700. The common contact point 714electrically connects rear surfaces of the plurality of the sensors 750.In addition, when the conductive foil 740 is adhered to a front surfaceof the copper coating or film 712, the common contact point 714 contactsa central conductive line 741 a formed at the conductive foil 740, andis electrically connected to negative electrodes of the plurality of thesensors 750. Thus, a current flows to the sensors 750.

Installation markings 715 mark exact positions of the elastic members720 and may be indicated at a rear surface of the sensor PCB 700. Theinstallation markings 715 may be formed by printing or other appropriatemethods. When the elastic members 720 are installed at the installationmarks 715, the elastic members 720 are installed at correct positions.The installation positions of the elastic members 720, i.e., thepositions of the installation markings 715, are formed at an outside ofthe sensor 750, and indicated at positions to face each other. Theinstallation markings 715 facing each other may be formed at the samedistance from a center of the sensor support portion 713.

The positions of the installation markings 715 may be at locationsgreater than outer ends of the sensors 750. Specifically, a separationdistance L between inner lines of the installation markings 715 facingthe center of the sensor 750 may be greater than an external diameter ofthe sensor 750, specifically, the metal plate 751. Accordingly, theelastic member 720 may not be interfered with the sensor 750 in adirection in which touch pressure is transmitted, and reduction in thesensitivity of the sensor 750 may be prevented.

As illustrated in FIG. 23, a spacer 730 may be interposed between thecopper coating or film 712 and the conductive foil 740 of the sensor PCB700. In the strict sense, the spacer 730 may be provided between the toplayer 716 and the conductive foil 740. The spacer 730 adheres theconductive foil 740 to the front surface of the sensor PCB 700, and mayinclude an adhesive member such as a double sided tape. In addition, aplurality of holes may be formed in the spacer 730.

Specifically, when the spacer is attached at the sensor PCB 700, theholes formed at the spacer 730 may include a plurality of sensor holes731 formed at positions corresponding to the sensors 750, and a contacthole 734 may be formed at a position corresponding to the common contactpoint 714 of the copper coating or film 712. When the conductive foil740 is attached to a front surface (or a top surface) of the spacer 730by the holes, the conductive foil 740 may contact the sensor 750 and thecommon contact point 714. The sensor hole 731 may have a size greaterthan the diameter of the sensor 750, and the sensor 750 may beaccommodated within the sensor hole 731. When the sensor 750 is deformedby touch pressure, the sensor is not interfered by the spacer 730.

In addition, bent holes or air escape holes 732 may be respectivelyformed at edges of the sensor holes 731. When the spacer 730 is attachedon the copper coating or film 712, the bent holes 732 serve as a paththrough which bubbles present between the spacer 730 and the coppercoating or film 712 are readily discharged to the outside. The bent hole732 extends from an edge of the sensor hole 731 to a predeterminedlength in a prescribed direction, e.g., lengthwise direction, of thespacer 730. The prescribed direction is based on the shape of the spacer730 and how the film spacer 730 is attached to the copper coating orfilm 712, e.g., the filmed shaped spacer 730 of the present disclosureis sequentially attached from one end of the copper coating or film 712toward an opposite end of the copper coating or film 712 in a lengthwisedirection. Accordingly, the bent hole 732 may extend from the edge ofthe sensor hole 731 in the same direction as a direction toward whichthe spacer 730 is attached in a predetermined length.

In addition, when the spacer 730 and the conductive foil 740 areattached on the copper coating or film 712, guide portions may beprovided at the spacer 730 and the conductive foil 740 so that thespacer 730 and the conductive foil 740 are attached to correctpositions. For example, the guide portion may include alignment throughholes 733 and 744 provided at the spacer 730 and the conductive foil740. The alignment through holes 733 and 744 may be formed in pluralnumber in a lengthwise direction of the spacer 730 and the conductivefoil 740, and may be alternately disposed at one side edge and the otherside edge in a widthwise direction of the spacer 730 and the conductivefoil 740.

In the sensor PCB 700, alignment rods 760 are disposed at positionscorresponding to the through holes 733 and 744. When the spacer 730 andthe conductive foil 740 are attached to the sensor PCB 700, thealignment rods 760 pass through the through holes 733 and 744. After thespacer 730 and the conductive foil 740 are sequentially attached to thesensor PCB 700, the alignment rods 760 may be removed from the sensorPCB 700. According to the above-described process, the spacer 730 andthe conductive foil 740 may be attached at correct positions on thesensor PCB 700 by the guide portion such that the center of the sensor750 may match a center of the sensor hole 731 of the spacer 730. Inaddition, the center of the sensor 750 may match a center of the contactportion 745 of the conductive foil 740 provided at the sensor PCB 700.

Referring to FIG. 24, the conductive foil 740 may include a transparentresin film material such as polyethylene terephthalate (PET), and may beformed to have a size corresponding to the sensor PCB 700 and the spacer730. A conductive line 741, which commonly connects top surfaces of theplurality of touch sensors 750 and the common contact point 714 formedat the copper coating or film 712, may be formed at a rear surface (or abottom surface) of the conductive foil 740. The conductive line 741 maybe printed using a silver material at a rear surface of the conductivefoil 740.

In addition, a surface in which the conductive line 741 is printed isformed to extend to contact a front surface (or a top surface) of thespacer 730 and to simultaneously contact the touch sensor 750 and thecommon contact point 714. The conductive line 741 may include thecentral conductive line 741 a and a peripheral conductive line 741 b.The central conductive line 741 a extends from a center of theconductive foil 740 in a lengthwise direction of the conductive foil740, and a peripheral conductive line 741 b is connected to the centralconductive line 741 a and is formed to extend in a grid shape or meshshape over an entire surface of the conductive foil 740. The centralconductive line 741 a may contact all of a top surface of the touchsensor 750 and the common contact point 714.

An inner guide line 742 may be formed in a circular shape at the rearsurface of the conductive foil 740 and enable correct position for touchsensor 750 attachment. The peripheral conductive line 741 b having thegrid shape may also be formed at an inside of the inner guide line 742.In addition, the central conductive line 741 a is connected to the innerguide line 742. An outer guide line 743 having a diameter greater than adiameter of the inner guide line 742 may be formed at an outside of theinner guide line 742. The inner guide line 742 and the outer guide line743 are also a part of the peripheral conductive line 741 b having thegrid shape, and may include a silver material. The inner guide line 742and the outer line 743 are bisected by the central conductive line.

The inner guide line 742 may be formed to correspond to a size of theceramic element 752, and the outer guide line 743 may be formed tocorrespond to a size of the metal plate 751. Accordingly, in a state inwhich the touch sensor 750 is installed at a correct position, an edgeof the ceramic element 752 may positioned to contact the inner guideline 742 and an edge of the metal plate 751 may be positioned to contactthe outer guide line 743.

The central conductive line 741 a extends from a center of the rearsurface of the conductive foil 740 in a lengthwise direction of theconductive foil 740, and connects a plurality of outer guide lines 743and inner guide lines 742. The conductive line 741 connects the commoncontact point 714 and the top surface of the touch sensor 750, that is,a negative electrode, and thus an electric current may be applied to thetouch sensor 750.

When a signal is generated by a touch input, a noise may be reduced bythe peripheral conductive line 741 b having the grid shape or meshshape. Since a conductive line having a grid shape is not formed betweenthe outer guide line 743 and the inner guide line 742, when the frontpanel 20 is pushed and deformed, deformation of the front panel 20 maybe effectively transmitted to the touch sensor 750.

Referring to FIG. 25, the touch booster 530 may be formed to have a sizecorresponding to the opening 512 of the housing cover 510, and formed tocover the opening 512. In addition, a plurality of hooks or clips 531formed at left and right sides of the touch booster 530 are coupled tothe hook grooves 514 formed at the housing cover 510. In addition, thehooks 531 are configured to allow forward or backward movement insidethe hook groove 514.

In addition, a plurality of elastic deformation portions or buttonscorresponding to the number of the sensors 750 may be formed at thetouch booster 530. The elastic deformation portions are formed atpositions corresponding to positions of the touch operation units 12 andthe sensors 750 of the front panel 20, and has elasticity to allowdeformation in a rearward direction, and to move in a forward directionbased on a restorative force. When a user pushes the touch operationunit 12, the touch operation unit 12 moves backward according todeformation of the front panel 20, and presses the elastic deformationportion. In addition, the elastic deformation portion presses the sensor750. When a user releases the touch input from the touch operation unit12, the elastic deformation portion returns to the original position.

The elastic deformation portion may include a first extension 532 whichextends from an edge of one side of an opening formed at the touchbooster 530 and is bent, a second extension 533 which extends from anedge of the other side of the opening and is bent, and a common portionor region 534 which is disposed at a center of the opening to connectend portions of the first extension 532 and the second extension 533.The second extension portion 533 may extend from a side opposite to thefirst extension portion 532.

The first extension 532 and the second extension 533 may be configuredto have a narrow width, to extend, to be bent at least one time, and tobe elastically deformable so that the common portion 534 moves in adirection of pressure and returns to the original position. The firstextension 532 and the second extension 533 may extend and be bent alongan edge of the common portion 534, and may be symmetrically formed withrespect to a plane which passes a diagonal line of the common portion534.

A remainder except the first extension 532, the second extension 533,and the common portion 534 forms a cut portion or a cut-out 536. Theprotrusive portion 535 may be formed to extend at a rear surface of thecommon portion 534. The protrusive portion 535 is positioned at a centerof the rear surface of the common portion 534, and is aligned with acenter of the sensor 750. The protrusive portion 535 is also formed tomaintain a contact state with an upper surface of the conductive foil740. Accordingly, when the common portion 534 is moved backward, acentral portion of the sensor 750 is pressed by the contact portion 745.

Referring to FIGS. 26 to 28, the touch sensor assembly 500 is attachedto the front panel 20 where the touch sensor assembly 500 is installedat the display cover 200. As the adhesive members 25 is provided to thefront surface of the display cover 200 and the front surface of thehousing cover 510, the display cover 200 and the touch sensor assembly500 may be adhered to the rear surface of the front panel 20.

The adhesive member 25 is not provided to the touch booster 530, and thetouch booster 530 is simply pressed or fitted against the rear surfaceof the front panel 20. When the touch sensor assembly 500 is installedat the display cover 200 and the touch sensor assembly 500 is attachedto the rear surface of the front panel 20, the touch booster 530 movesbackward and the elastic member 720 is compressed based on the touchinput on the front panel. The sensor PCB 700 is pressed forward by arestoring force of the elastic member 720, and as a result, the sensorPCB 700 is pressed against the touch booster 530. In addition, the touchbooster 530 may be moved forward or backward by touch pressure when thetouch booster 530 is coupled to the housing cover 510.

In the above-described state, when a user touches the touch operationunit 12 of the front panel 20, a movement displacement of the frontpanel 20 is generated at a region on which the front panel 20 istouched. The movement displacement of the front panel 20 is immediatelytransmitted through the touch booster 530 to press the sensor 750. As aresult, a touch signal is generated from the sensor 750, and acontroller of the refrigerator senses a user's touch operation.

As the touch booster 530 moves backward by a user's touch of the frontpanel 20, the elastic member 720 may be increasingly compressed. Whentouch input is removed from the touch operation unit 12, the sensor PCB700 and the touch booster 530 move forward and return to a previousstate by a restoring force of the elastic member 720, the elasticdeformation portion of the touch booster 530, and the metal plate 751 ofthe sensor 750. The elastic member 720 configured to press and supportthe sensor PCB 700 may be formed to have various shapes to provideuniform pressure to the sensor PCB 700 when the sensor housing iscoupled thereto.

Meanwhile, a manufacturing method of a door having the above-describedstructure according to an embodiment of the present disclosure will bedescribed hereinafter.

Referring to FIGS. 29 to 30, the front panel 20 is formed of aplate-shaped stainless steel to manufacture the door 10. The pluralityof first through holes 21 which constitute the display window 11 may beformed at the front panel 20 using an etching or a laser processing. Thefirst through holes 21 may be filled with the sealing member 22, and thediffusive sheet 26 may be attached to the rear surface of the frontpanel 20 in which the first through holes 21 are formed (see FIG. 13).In addition, the touch operation unit 12 may be formed at the frontpanel 20 using an etching, a surface processing, or a printing.

When the front panel 20 is completely formed, the touch sensor assembly500 is assembled. In order to assemble the touch sensor assembly 500,first, after the sensor PCB 700 is formed, the touch sensor 750 isinstalled at a top surface (or a front surface) of the sensor PCB 700,and the elastic member 720 is attached onto a bottom surface (or a rearsurface) thereof. In addition, the spacer 730 and the conductive foil740 are sequentially stacked and attached onto the front surface of thesensor PCB 700. A cover member 770, which covers a rear end opening ofthe sensor support portion 713 and seals an inside of the sensor supportportion 713, is adhered to the rear surface of the sensor PCB 700.

The above-described sequential manufacturing process will be describedin detail with reference to a flowchart of FIG. 30. An insulatingsubstrate 717 forming a base of a sensor PCB 700 is formed. Theinsulating substrate 717 may be formed of at least one of an epoxy resinor glass fiber, and may be formed to have the same size of the sensorPCB 700 (S110).

After the insulating substrate 717 is formed, a copper coating or film(or conductive layer) 712 is coated on a top surface of the insulatingsubstrate 717 using a coating or deposition process. In a state in whichthe copper coating or film 712 is formed, patterns, such as signallines, power lines, and ground lines, are formed using screen printingand etching processes. Other than the sensor support portion 713. Thecopper coating or film 712 may be formed on the insulating substrate.

Thereafter, a top layer 716, which protects the copper coating or film712, may be formed (S130). The top layer 716 is formed of a resinmaterial, and is formed to cover the copper coating or film 712 using aprinting process. As the top layer 716 is formed outside of the sensormounting portion 718 and the sensor support portion 713, the sensormounting portion 718 is exposed to the outside. The sensor mountingportion 718 have the same or substantially the same circular shape as acircular metal plate 751 of the touch sensor 750, and a diameter thereofis greater than that of the circular metal plate 751. The sensormounting portion 718 may also have a width so that the soldering spot715 may be printed and the metal plate 751 may be seated.

After the top layer 716 is formed, a sensor support portion 713 whichpasses through the sensor PCB 700 may be formed (S140). A diameter ofthe sensor support portion 713 may be greater than a diameter of aceramic element 752 of the touch sensor 750, and may be smaller than adiameter of the metal plate 751. The touch sensor 750 may be stablysupported, and the sensitivity of the touch sensor 750 may be optimallymaintained. The sensor mounting portion 718 is formed at an outer sideof the sensor support portion 713.

Next, at least one soldering spot 715 is formed at the sensor mountingportion 718 by printing solder cream. One to three of the solderingspots 715 may be formed, and thinly coated on an inner side of thesensor mounting portion 718 (S210).

The sensor PCB 700 on which the soldering spot 715 is formed istransferred to a position for attachment of the touch sensor 750 (S220).The touch sensor 750 may be supplied by a feeder, and may be mounted ata correct position on the sensor mounting portion 718. As the touchsensor 750 presses the soldering spot 715, the solder cream is thinlyspread on the sensor mounting portion 718. As a result, the touch sensor750 may be mounted in a horizontal state without being inclined due tosoldering spot 715. Thereafter, the sensor PCB 700 is transferred to aheating furnace to cure the soldering spot 715 is cured to fix the touchsensor 750 against the sensor mounting portion 718.

In order to adhere the spacer 730 and the conductive foil 740 in stepS300, the alignment rod is disposed at a predetermined position of thesensor PCB 700, and the spacer 730 is attached where a through hole 733passes through the alignment rod of the spacer 730. Accordingly, thespacer 730 may be attached to a correct position on the top surface ofthe sensor PCB 700.

The spacer 730 is attached thereto in a direction toward which the benthole 732 extends, and bubbles generated while the spacer 730 is attachedmay be discharged through the bent hole 732. When the spacer 730 iscompletely attached thereto, the conductive foil 740 is attached to atop surface of the spacer 730.

Like the spacer 730, the through hole 744 is attached thereto to passthrough the alignment rod, the conductive foil 740 is attached to acorrect position, and the conductive foil 740 and the spacer 730 arealigned accurately in step S400. As the conductive foil 740 is graduallyattached thereto from an end portion of one side in the direction towardwhich the bent hole 732 extends, bubbles are not trapped in theconductive foil 740 and the spacer 730. When the conductive foil 740 isattached to a correct position, an edge of an outside of the sensor 750is correctly interposed between the inner guide line 742 and the outerguide line 743.

After the above-described processes, the sensor PCB 700 is accommodatedin the housing body 520, and the housing cover 510 in which the touchbooster 530 is installed is coupled to the housing body 520. When thehousing cover 510 and the housing body 520 are coupled, the elasticmember 720 is compressed, the sensor PCB 700 is pressed, and as aresult, the sensor PCB 700 is pressed against the touch booster 530. Thetouch booster 530 is installed thereto to move forward or backward, andthe front surface of the touch booster 530 protrudes more than the frontsurface of the housing cover 510.

The completely assembled touch sensor assembly 500 is seated on theaccommodation portion 210 of the display cover 200, the housing couplingportion 511 is coupled to an edge of an upper side of the accommodationportion 210, and a state in which the touch sensor assembly 500 is fixedto the display cover 200 is maintained. After the adhesive member 25 isattached to the front surfaces of the display cover 200 and the housingcover 510, the display cover 200 and the touch sensor assembly 500 aresimultaneously attached to the rear surface of the front panel 20.

When the display cover 200 is attached to the front panel 20, the frame100 is fixed to the front panel 20 so that the display cover 200 isaccommodated therein. In addition, the door liner 30 is coupled to therear surface of the front panel, and the deco members 40 are coupled toupper ends of the front panel 20 and the door liner 30. Thereafter, afoam solution is foamed inside of the door 10, and the heat insulatingmaterial 24 is formed. The heat insulating material 24 fills an entireinner space of the door 10 except an inside of the frame 100, and stablyfixes the frame 100.

In a state in which the heat insulating material 24 is completely formedin an inside of the door 10, the display assembly 300 is installed atthe display frame 400. A worker also connects the first cable connector610 connected to the sensor PCB 700 and the second cable connector 620connected to the display PCB 310. Because the connection between thefirst cable connector 610 and the second cable connector 620 isperformed after the heat insulating material 24 is completely formed,possible damage of the sensor controller 330 caused by staticelectricity generated while the heat insulating material is formed byfoaming a foam solution may be prevented.

After the first cable connector 610 and the second cable connector 620are connected to each other, the display frame 400 is installed in theinside of the door 10 through the insertion hole 41, and the displayframe 400 is completely inserted into the display cover 200 using theframe handle 420. After complete insertion, the display assembly 300 iscompletely pressed against the rear surface of the display cover 200. Inaddition, the first through hole 21, the second through hole 220, andthe third through hole 321 are aligned and communicated with each otherfrom front to back.

After the display frame 400 is completely inserted, the insertion holecover 42 is installed at the insertion hole 41, and the insertion hole41 is closed. In addition, the upper end of the frame handle 420 isfixed by the insertion hole cover 42, and the door 10 is completelymanufactured.

The door according to the embodiment of the present disclosure may notbe limited to the above-describe embodiment, and other embodiments maybe suggested. In another embodiment of the present disclosure, a touchbooster is directly attached to the display cover, a housing body iscoupled to the display cover, and a space which accommodates a sensorPCB is formed.

Another embodiment of the present disclosure has the same structureexcept structures of a display cover and a touch sensor assembly, andthe same reference number refers to the same component in the drawings.Redundant description thereof will be omitted.

FIG. 31 is an exploded perspective view illustrating a structure of adisplay cover and a sensor housing according to another embodiment ofthe present disclosure. A display cover 200 is attached to a rearsurface of a front panel 20 of a door 10 according to another embodimentof the present disclosure, and a touch sensor assembly 500 including atouch booster 530, a sensor PCB 700, and a housing body 520 is coupledto the display cover 200.

A plurality of second through holes 220 are formed in one side of thedisplay cover 200, and a booster insertion portion 250 is formed at theother side thereof which is spaced in a side direction from a region inwhich the second through holes 220 are formed. The booster insertionportion 250 is opened to have a size corresponding to the touch booster530. An extending rib 251 may be formed to extend backward at an edge ofthe booster insertion portion 250, and the extending rib 251 guides aforward and backward movement of the touch booster 530.

An extending rib may also be formed to extend backward at an edge of theaccommodation portion 210 of the display cover 200 according to theprevious embodiment of the present disclosure. Unlike the extending rib251, the extending rib which extends backward from both sides of theaccommodation portion 210 may support a side portion of the touch sensorassembly 500.

A booster support portion 252 protrudes and extends from an innercircumferential surface of the booster insertion portion 250 and isconfigured to support the touch booster 530 from a backward direction.The booster support portion 252 may be formed in the same shape as thebooster support portion 513 in FIG. 14, and may perform the samefunction.

A part of the booster support portion 252 is cut, and forms a hookgroove 253 like the hook groove 514 in FIG. 14. In addition, a hook 531formed at both sides of the touch booster 530 moves backward along thehook groove 253, and is hooked on a rear side of the extending rib 251.The hook groove 253 may be completely opened backward, and the touchbooster 530 may move forward or backward by touch pressure.

The housing body 520 is coupled to a rear side of the booster insertionportion 250. The housing body 520 is coupled to a rear surface of thedisplay cover 200, and forms a space which accommodates the sensor PCB700. To this end, a plurality of body coupling portions 521 are formedat left and right sides of the housing body 520, and the plurality ofbody coupling portions 521 may be formed in a hook shape. Couplingportions configured to be coupled to the body coupling portion 521 maybe formed at the rear surface of the display cover 200 corresponding tothe body coupling portion 521.

An installation guide 523 configured to guide a plurality of elasticmembers 720 which support the sensor PCB 700 is formed to protrude andextend at an inside of the housing body 520 in a rib shape. As alreadydescribed in FIG. 14, the installation guide 523 enables the elasticmembers 720 not to be inclined in one direction when the elastic members720 are compressed.

Touch sensors 750 are disposed at a front surface of the sensor PCB 700,and a spacer 730 and a conductive foil 740 are sequentially adhered tothe front surface of the sensor PCB 700 in which the touch sensors 750are disposed. As described in the previously, since the touch sensor 750covers a front surface of the sensor support portion 713 formed at thesensor PCB 700, and the cover member 770 covers the rear surface of thesensor support portion 713, airtightness of the sensor support portion713 may be maintained.

The sensor PCB 700 is accommodated in an inside of the housing body 520,and is pressed by the elastic members 720 when the housing body 520 iscoupled to the display cover 200. The sensor PCB 700 moves forward andthe front surface thereof contacts the touch booster 530, and a frontsurface of the touch booster 530 protrudes more than a front surface ofthe display cover 200. As a result, a state in which the touch booster530 is strongly pressed against a rear surface of the front panel 20 maybe maintained.

Adhesive members 25 may be provided at a remaining part of the displaycover 200 except the booster insertion portion 250 in a state in whichthe touch sensor assembly 500 is coupled to the display cover 200. Inaddition, the display cover 200 is attached to the rear surface of thefront panel 20 using the adhesive members 25. Here, even though thetouch booster 530 is not adhered to the front panel 20, a state in whichthe touch booster 530 is always pressed against the front panel 20 ismaintained.

In addition, a state in which an end portion of the protrusive portion535 of the touch booster 530 always contacts a front surface of theconductive foil 740 is maintained, and a state in which a surfaceopposite the front surface of the conductive foil 740 which contacts theprotrusive portion 535 is pressed against the touch sensor 750 ismaintained. Accordingly, a displacement generated during a touchoperation of a touch operation unit 12 may be immediately transmittedthrough the protrusive portion 535 and the contact portion 745 to thetouch sensor 750.

Meanwhile, the touch sensor assembly according to one embodiment may notbe only provided at the door according to the previous embodiment, butmay also be provided at refrigerators having various types. As a touchsensor assembly which will be described below has the same structure asthe above-described touch sensor assembly, the same reference numberrefers to the same component in the drawings. Redundant descriptionthereof will be omitted.

FIG. 32 is an exploded perspective view illustrating a structure inwhich the touch sensor assembly according to one embodiment of thepresent disclosure is installed at a door having another type. A door 50in which a touch sensor assembly 500 is installed may include a doorcase 51 in which a heat insulating material is accommodated, a pair ofcap decos 52 disposed at upper and lower sides of the door case 51, apair of side decos 53 disposed at left and right sides of the door case51 and coupled to a door handle 54, and a front panel 55 coupled to afront surface of the door case 51. The front panel 55 may be fixed tothe front surface of the door case 51 by the pair of cap decos 52 andthe side decos 53.

The front panel 55 may be formed of tempered glass or a plasticmaterial, and a film may be printed on a front surface of the frontpanel 55. A display window 56 showing an operation state of arefrigerator may be formed at the front panel 55, and a touch operationunit 57 may be formed at one side of the display window 56. The displaywindow 56 may be formed in a transparent or translucent type to seetherethrough. The touch operation unit or area 57 may be formed using aprinting or a surface processing. The display window 56 and the touchoperation unit 57 are the same as the display window 11 and the touchoperation unit 12 described in the previous embodiment.

A display cover 200 may be adhered and fixed to a rear surface of thefront panel 55 corresponding to a rear side of the display window 56. Asdescribed in the previous embodiment, the touch sensor assembly 500 anda display assembly 300 may be installed at the display cover 200.According to the present embodiment, the display cover 200 isindependently interposed between the door case 51 and the front panel 55without a frame 100. To this end, the front panel 55 is spaced adistance corresponding to a thickness of the display cover 200 from thefront surface of the door case 51 by the cap decos 52 and the side decos53.

When the display cover 200 is attached to the rear surface of the frontpanel 55, light output from the display assembly 300 may be emittedthrough the display window 56 to the outside, and an operation state ofthe refrigerator may be shown to the outside. The touch sensor assembly500 is pressed against a rear surface of the touch operation unit 57,and recognizes the touch operation when a user touches the touchoperation unit 57.

FIG. 33 is an exploded perspective view illustrating a structure inwhich the touch sensor assembly according to one embodiment of thepresent disclosure is installed at an air conditioner. An indoor unit 60of an air conditioner which includes a touch sensor assembly 500includes a base 61, a rear cabinet 62 disposed at a rear side of a topsurface of the base 61, and a front cabinet 63 disposed at a front sideof the top surface of the base 61. In addition, an exterior member 64may be disposed at a front surface of the front cabinet 63.

The base 61, the rear cabinet 62, and the front cabinet 63 are coupledto each other, and form a predetermined space. A blower fan and a flowpath configured to draw in or discharge air are provided in the space,and a filter assembly configured to filter drawn-in air, and acompressor, a condenser, an expansion valve, and an evaporator whichconstitute a freezing cycle are accommodated in the space.

The indoor unit 60 may include a intake hole 631 which draws in indoorair, and a plurality of discharging holes 632 through which the suckedair through the intake hole 631 exchanges heat using the evaporator andis discharged to an interior.

The exterior member 64 may be pivotably and detachably installed at thefront cabinet 63. Hinges 601 may be installed at upper and lower ends ofthe front cabinet 63, and the hinge may be inserted into top and bottomsurfaces of side end portions of the exterior member 64. The exteriormember 64 may be pivotably connected to the front cabinet 63 by thehinges 601. Further, the exterior member 64 may be separated from thehinges 601.

A front side of the front cabinet 63 may be opened by pivoting ordetaching of the exterior member 64, and maintenance and repair ofelectric components provided at the front cabinet 63 may be performed.Alternatively, the exterior member 64 may be fixed and installed to thefront cabinet 63.

A transparent display window 65 configured to show an operation state ofthe air conditioner may be formed at the exterior member 64, and a touchoperation unit or touch input area 66 may be indicated at one side ofthe display window 65 by a printing or a surface processing. A displayassembly 67 may be provided in the rear of the display window 65, and aslight emitted from the display assembly 67 passes through the displaywindow 65 to the outside, operation information of the indoor unit maybe shown. The display assembly 67 may be constituted by a combination ofLEDs, may also provide information in a numeral or symbol type, and mayalso provide information using pictures or images by being constitutedby liquid crystal displays (LCDs) theretogether.

The touch sensor assembly 500 may be attached at a rear surface of theexterior member 64 corresponding to the touch operation unit 66. Thetouch sensor assembly 500 is adhered by an adhesive member such as anadhesive or double sided tape, and the touch sensor assembly 500 may bepressed against the touch operation unit 66 and recognize a user's touchoperation.

FIG. 34 is an exploded perspective view illustrating a structure inwhich the touch sensor assembly according to one embodiment of thepresent disclosure is installed at a washing machine. A washing machine70 which includes a touch sensor assembly 500 may include a main body 71forming an exterior, a tub which is accommodated in the main body 71 andstores wash water, a drum which is disposed in an inside of the tub andaccommodates laundries, a driving unit which transmits a rotating forcefor rotating the drum, a wash water supplying unit which supplies thewash water to the tub, and a discharging unit configured to dischargethe wash water.

A part of a front surface of the main body 71 is formed to be open toput the laundries into the drum, and an opening of the main body 71 isopened or closed by a door 72. The door 72 is pivotably installed at themain body 71. An exterior member 73 having a plate shape may be providedat an upper side of a front surface of the main body 71 except the door72. In addition, a display window 74 and a touch operation unit or atouch input area 75 may be formed at the exterior member 73.

The display window 74 shows an operation state of the washing machine70, and an operation and operation option of the washing machine 70 maybe selected by touch operation of the touch operation unit 75. A knob 76having a dial shape for operation of the washing machine 70 may beprovided at the front surface of the main body 71, and the knob 76 maypass through the exterior member 73 and be exposed to the outside.

A display assembly 77 may be provided in the rear of the display window74, light may be emitted to the display window 74 by the displayassembly 77, and operation information of the washing machine 70 may bedisplayed. The display assembly 77 may be formed with a combination ofLEDs, may also provide information in a numeral or symbol type, and mayalso provide information using pictures or images by being formed withliquid crystal displays (LCDs) theretogether.

The touch sensor assembly 500 may be attached to a rear surface of theexterior member 73 corresponding to the touch operation unit 75. Thetouch sensor assembly 500 may be adhered by an adhesive member such asan adhesive or a double sided tape, and the touch sensor assembly 500may be pressed against the touch operation unit 75, and may recognize auser's touch operation.

FIG. 35 is an exploded perspective view illustrating a structure inwhich the touch sensor assembly according to one embodiment of thepresent disclosure is installed at a dishwasher. An exterior of adishwasher 80 including a touch sensor assembly 500 is formed by a mainbody 81 formed in a roughly rectangular hexahedron shape. Within aninside of the main body 81, a cavity which accommodates dishes to wash,rack members which are inserted into or withdrawn from the cavity and inwhich the dishes are seated, a water supplying unit which supplies washwater to an inside thereof to wash, a discharging unit which dischargesthe used wash water, and the like may be included.

Doors 82 may be provided at the dishwasher main body 81. The doors 82are configured to selectively cover an opened front surface of the mainbody 81, and form an exterior of a front side of the dishwasher 80 in astate in which the doors 82 are closed. The doors 82 may be formed withan upper door and a lower door, and when the lower door operates, theupper door may be opened or closed in conjunction therewith. A handle 83configured to open or close the doors 82 may be provided at the lowerdoor.

Exterior members 84 which form an exterior are attached at frontsurfaces of the doors 82, that is, front surfaces of the upper door andthe lower door. A transparent display window 85 configured to show anoperation state of the dishwasher 80 may be formed at the exteriormember 84, and a touch operation unit or a touch input area 86 may beprovided at one side of the display window 85 by a printing or a surfaceprocessing.

A display assembly 87 may be provided in the rear of the display window85, light may be emitted to the display window 85 by the displayassembly 87, and operation information of the dishwasher 80 may bedisplayed. The display assembly 87 may be constituted by a combinationof LEDs, may also provide information in a numeral or symbol type, andmay also provide information using pictures or images by beingconstituted by liquid crystal displays (LCDs) theretogether.

The touch sensor assembly 500 may be attached to a rear surface of theexterior member 84 corresponding to the touch operation unit 86. Thetouch sensor assembly 500 may be adhered by an adhesive member such asan adhesive or a double sided tape, and the touch sensor assembly may bepressed against the touch operation unit, and may recognize a user'stouch operation.

FIG. 36 is an exploded perspective view illustrating a structure inwhich the touch sensor assembly according to one embodiment of thepresent disclosure is installed at a cooker. An exterior of a cooker 90including a touch sensor assembly 500 according to an embodiment of thepresent disclosure is formed by a main body 91 formed in a roughlyrectangular hexahedron shape. The cooker main body 91 may include acavity which accommodates food to cook, a heating unit or magnetronconfigured to cook food inside the cavity, and a fan assembly whichcirculates air inside the cavity.

A door 92 may be pivotably provided at the cooker main body 91. The door92 is provided to selectively cover an opened front side of the cookermain body 91, and forms a front side exterior the cooker 90 in a statein which the door 92 is closed. The door 92 may be hinge-coupled to thecooker main body 91, may be horizontally or vertically pivotable, andmay selectively open or close an opened front side of the cooker 90.

A handle 93 for an opening or closing operation of the door 92 isprovided at the door 92. An exterior member 94 forming a front sideexterior of the door 92 may be provided at a front surface of the door92. The exterior member 94 may also form one side of the cooker mainbody 91 without being limited to the door 92.

A transparent display window 95 configured to display an operation stateof the cooker 90 may be formed at the exterior member 94, and a touchoperation unit 96 may be formed at one side of the display window 95 bya printing or a surface processing.

A display assembly 97 may be provided in the rear of the display window95, and operation information of the cooker may be displayed by thedisplay assembly 97 emitting light to the display window 95. The displayassembly 97 may be constituted by a combination of LEDs, may alsoprovide information in a numeral or symbol type, and may also provideinformation using pictures or images by being constituted by liquidcrystal displays (LCDs) theretogether.

The touch sensor assembly 500 may be attached to a rear surface of theexterior member 94 corresponding to the touch operation unit 96. Thetouch sensor assembly 500 may be adhered by an adhesive member such asan adhesive or a double sided tape, and the touch sensor assembly may bepressed against the touch operation unit 96, and may recognize a user'stouch operation.

This application relates to U.S. application Ser. No. 14/931,776 filedon Nov. 3, 2015, and U.S. application Ser. Nos. 14/977,572, 14/977,588,14/977,615, and Ser. No. 14/977,623, all filed on Dec. 21, 2015, whichare hereby incorporated by reference in their entirety. Further, one ofordinary skill in the art will recognize that features disclosed inthese above-noted applications may be combined in any combination withfeatures disclosed herein.

Any reference in this specification to “one embodiment,” “anembodiment,” “example embodiment,” etc., means that a particularfeature, structure, or characteristic described in connection with theembodiment is included in at least one embodiment of the invention. Theappearances of such phrases in various places in the specification arenot necessarily all referring to the same embodiment. Further, when aparticular feature, structure, or characteristic is described inconnection with any embodiment, it is submitted that it is within thepurview of one skilled in the art to effect such feature, structure, orcharacteristic in connection with other ones of the embodiments.

Although embodiments have been described with reference to a number ofillustrative embodiments thereof, it should be understood that numerousother modifications and embodiments can be devised by those skilled inthe art that will fall within the spirit and scope of the principles ofthis disclosure. More particularly, various variations and modificationsare possible in the component parts and/or arrangements of the subjectcombination arrangement within the scope of the disclosure, the drawingsand the appended claims. In addition to variations and modifications inthe component parts and/or arrangements, alternative uses will also beapparent to those skilled in the art.

What is claimed is:
 1. A touch sensor assembly comprising: an insulatingsubstrate formed of a resin material; a conductive layer printed on anupper surface of the insulating substrate to form a printed circuit; aprotective layer provided over an upper surface of the conductive layer;a plurality of sensor mounting areas formed by the upper surface of theconductive layer, which are exposed through the top layer; a touchsensor including a metal plate in contact with an upper surface of thesensor mounting area, and a ceramic element provided on an upper surfaceof the metal plate; a conductive foil covering the protective layer andthe touch sensor; and a spacer interposed between the protective layerand the conductive foil, wherein the spacer includes: a plurality ofsensor holes which are formed at positions corresponding to the sensormounting areas; and a plurality of air escape holes which extend fromedges of the plurality of sensor holes to discharge bubbles generatedbetween the spacer and the conductive layer during attachment of thespacer, wherein each of the plurality of air escape holes extend in alengthwise direction of the spacer and are collinear with each otheralong a bisector that runs through a center of each of the plurality ofsensor holes, wherein the lengthwise direction of the spacer is asequential direction of the plurality of sensor holes, and wherein adiameter of each of the plurality of sensor holes corresponds to anouter diameter of each of the plurality of sensor mounting areas.
 2. Thetouch sensor assembly of claim 1, wherein the spacer further includes: afirst through hole formed at one side of the spacer; and a secondthrough hole formed at the other side of the spacer, wherein the firstthrough hole and the second through hole are spaced apart from eachother in the lengthwise direction of the spacer.
 3. The touch sensorassembly of claim 2, wherein the conductive foil includes a thirdthrough hole and a fourth through hole which are formed at positionsrespectively corresponding to positions of the first and second throughholes of the spacer.
 4. The touch sensor assembly of claim 1, wherein ahole is provided in each of the plurality of sensor mounting areas ofthe insulating substrate to form a sensor support, and the outerdiameter of each of the plurality of sensor mounting areas is largerthan a diameter of the sensor support.
 5. The touch sensor assembly ofclaim 4, further comprising a cover film attached onto a rear surface ofthe insulating substrate to cover the hole to form the sensor support.6. The touch sensor assembly of claim 1, further comprising at least onesolder contact provided on an upper surface of each of the plurality ofsensor mounting areas to fix the touch sensor to the sensor support, atleast one solder contact being a cream prior to curing.
 7. The touchsensor assembly of claim 1, further comprising a conductive line formedon a lower surface of the conductive foil.